Rivera Primo Dual Runner Intake Manifold with 45mm Mikuni Carburetor Kit (DRM) - Manual (Page 2)

DUAL DUAL RUNNER MANIFOLD RUNNER MANIFOLD
DUAL DUAL CARBURET CARBURET OR INST OR INST ALLA ALLA TION TION
DUAL DUAL RUNNER MANIFOLD RUNNER MANIFOLD
DUAL DUAL CARBURET CARBURET OR INST OR INST ALLA ALLA TION TION
2
3
INSTALLATION INSTRUCTIONS
for
RIVERA ENGINEERING’S
DUAL CARBURETOR DUAL
RUNNER INTAKE MANIFOLD KIT
SAFETY PROCEDURES
NOTES, CAUTIONS and WARNINGS
Instructions preceded by these words are important.
NOTE
Information that can make a job easier.
CAUTION
The possibility of damage to the vehicle exists.
WARNING
The possibility of injury to yourself or others exists.
Read the installation instructions thoroughly prior to the
installation of this Rivera dual-carb kit. All procedures
should be followed exactly as described in this manual, pay-
ing particular attention to the following:
WARNING
1. THIS MIKUNI VERTICAL SLIDE THROTTLE VALVE CAR-
BURETOR REQUIRES THE USE OF A PULL OPEN / PULL
CLOSED THROTTLE ASSEMBLY to assure positive closing
of the throttle valve (slide). The high vacuum encountered,
as well as dirt or other particles ingested into the carburetor
when the motor is running without an air filter, may prevent
the throttle slide from closing promptly and or completely.
2. On installation, the THROTTLE CABLES SHOULD BE
ROUTED FREELY (WITHOUT SHARP BENDS) BETWEEN
THE THROTTLE TWIST GRIP AND THE CARBURETOR. The
throttle cables should not be pinched by the installed fuel
tank, and they should not be pinched, pulled or restricted by
the motorcycle body work and/or the front fork assembly
when it is turned through the full range of motion.
3. GASOLINE IS EXTREMELY FLAMMABLE & IS EXPLOSIVE
UNDER CERTAIN CONDITIONS. Before attempting to install
or service your Rivera dual-carbs, follow these fire safety
procedures:
· Make sure your work area is well ventilated and free from
any source of flame or sparks, i.e., appliances with pilot
lights, such as water heaters, clothes dryers or space
heaters, etc.
· Before removing the motorcycle fuel tank, be sure the fuel
petcock is in the "OFF" position and the cross-over fuel line
is well clamped. Clean up any fuel spills immediately.
4. Never look directly into the bores of the carburetors while
the engine is running as injury may result from possible
backfire.
CAUTION
Be patient. Due to the very limited clearances between
the manifold and cylinders extra care must be taken to
ensure that the manifold bolts are installed correctly,
and not cross threaded. The gas tank and top motor
mount must be removed to allow installation. A mod-
erate degree of mechanical skill is required to proper-
ly install this dual-carb dual runner intake manifold kit.
If after reading these instructions you have any doubts
about your ability to perform a proper installation, it is
recommended that you have a professional mechanic
install it for you. If you install the kit yourself we rec-
ommend that you refer to the appropriate and or appli-
cable maintenance or shop manual for your particular
model motorcycle.
TOOLS REQUIRED
These are the tools typically required to remove the
stock carburetor and install the Rivera dual-carb kit.
1. Allen wrenches, 1/8", 5/32", 1/4" & 5/16"
2. Standard wrenches, 7/16 1/2", 9/16", 12 point 1/4" &
5/16" wrenches (a 5/16 wrench for limited space).
3. Diagonal cutters (dykes)
4. Slotted and #2 Phillips screwdrivers
5. Blue Loctite or equivalent
7. Shop Manual (for your model)
DISASSEMBLY
1. Disconnect the negative (-) battery terminal.
2. Turn the fuel petcock to the "OFF" position.
3. Remove the gas tank from the motorcycle, and the
top motor mount.
4. Remove the existing (OEM) air cleaner assembly.
6. Remove vacuum hoses & fuel hose from the carb.
7. Remove the carburetor assembly (and choke cable
assembly) from the motorcycle. The throttle cable
adjusters will need to be loosened to allow the cables
to be disconnected from the carburetor. The Rivera
dual-carb was designed to be operated with standard
1990 and later Harley-Davidson throttle cables.
8. Remove the OEM intake manifold and flanges;
these parts will not be reused.
DUAL RUNNER
MANIFOLD INSTALLATION
A. Attach the Rivera dual-carb manifold using the enclosed
flange, seals and 12 point 5/16" cap screws. The rear cylin-
der flange is marked with "R" and the front with "F". Place 2
of the 12 point cap screws in the flanges then slip the flanges
and seals and onto the manifold. Loosely secure the mani-
fold to the cylinder
heads with all four cap screws. This
is where a 12 point 5/16" wrench designed for limited
space is required; for tightening the two manifold bolts
on the side of the manifold away from the horn. These
4 bolts can be a bit tedious to tighten, but with the cor-
rectly shaped wrench can be tightened with a mini-
mum of effort.
B. Attach the manifold top support bracket to the cylin-
ders in the appropriate method for your type engine:
NOTE
The top support bracket also incorporates a cylinder
head breather system which includes 2 tube vents
tubes attached to the backside side.
Pre 1992 motor use 2 each 5/16" x 1" bolts, 2 each.
5/16" conical washers from this kit.
1992 & up motors (with 1/2" mounting/ breather holes)
use 2 each 1" hollow socket head bolts from this kit.
Twin Cam kits use 2 3/8” hollow breather bolts which
are included.
C. Once you have determined the correct support
bracket mounting for your model, attach the bracket
loosely and secure the manifold to the support brack-
et with the enclosed 3/8" x 1 1/2" bolt, flat and lock
washers. A spacer is included to place between the
top support bracket and the intake manifold to allow
for proper gas tank/carburetor clearance. Use addi-
tional spacers as required to keep the carburetors
from contacting the gas tank. Tighten the intake man-
ifold bolts and top mount bracket.
D. A lower support assembly is included in each kit to
further support the weight of the manifold and carbu-
retor assembly. This support consists of a 2 piece
bracket assembly; one piece attaches to the boss on
the underside of the manifold and the second attaches
between the tappet guide blocks. The 2 pieces are
bolted together, forming the lower support assembly.
Use the stock tappet block bolts to secure the bottom
piece of the bracket assembly with the 2 each ¼" flat-
washers from the kit placed between the bracket and
the guide block casting*. Twin Cam models use the 2
mounting bolts nearest the cylinders. EVO models use
the 2 mounting bolts furthest from the cylinders.
Attach the long portion of the mounting bracket to the
boss on the underside of the intake manifold with the
3/8" bolt, flat and lock-washers from the kit. Use the
enclosed 5/16" bolt, flat-washer and flanged nut to join
the two pieces of the bracket together. The bracket
holes are slotted to allow for differences in engine
dimensions.
CAUTION
Some after-market tappet guide blocks use recessed
screw holes for the attaching screws. If yours are of
this type, spacers will be needed to keep the lower
support bracket from damaging the blocks as the
mounting screws are tightened.
CARBURETOR INSTALLATION
A. Attach the carburetor assembly to the intake manifold with
the 4 each 3/8" x 1" socket head bolts and thin 3/8" lock-
washers and flat washers, tighten them securely.
CAUTION
With rubber mounted motors, check the clearance between
the gas tank and the carburetors, there should be a minimum
of 1/2" at the closest point. If the clearance is less than this
amount, place the 1/8" thick chrome spacer, included in the
kit, between the intake manifold boss and the support brack-
et to create more gas tank clearance.
Having less than 1/2" gas tank clearance may allow the car-
buretors to contact the gas tank as the engine moves during
normal operation.
THROTTLE CABLES
CAUTION
The Rivera dual-carb kit was designed to use 1990 and later
OEM throttle cables. Before attaching the throttle cables,
assure that they are in good operating condition and well
lubricated.
A. Check to assure that the throttle cable adjusters are com-
pletely backed-off. Insert the end of the opening cable into
the throttle wheel in the position indicated; do-not insert the
cable housing into the cable bracket at this time. Insert the
end of the closing cable in the remaining throttle wheel hole
(hold the opening cable out of the way as necessary) and
insert the cable housing into the cable bracket.
B. Insert the opening cable housing into the cable bracket.
The cables overlap in the throttle wheel between the two
holes but do-not rub against each other during operation.
ATTACHING THE THROTTLE CABLES
C. Check the throttle for smooth operation. Open the throt-
tle to the full open position and look into the bore of the car-
buretors to verify that the throttle valves are fully raised out
of the bores. If they are not, adjust the opening throttle cable
until the throttle valves clear the bores.
D. Adjust the throttle "free-play" to approximately 1/8" as
indicated by using the closing throttle cable adjuster to
remove excess cable play.